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Forum LockedMy Diy custom air intake system!

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UKDaveJ View Drop Down
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Joined: 18-November-2004
Location: Bromsgrove, Worcestershire
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Direct Link To This Post Topic: My Diy custom air intake system!
    Posted: 16-February-2006 at 19:43
Below you will see a picture that doesn't perhaps portray the thought & effort that has gone into it, but its now on my Highline anyway!!

Essentially my 'kit' contains;

1 x K&N cone filter (bought from Tusker sometime ago),

1 x custom-rolled galvanised steel nominal 6" to 3" cone, with a spigot on both ends,

1 x stainless steel 3" 'elbow' (free from Jay at MIJ who made my exhaust),

1 x short length of samco hose.

1 x plumbers heat mat (rated to 750'C)

Approx 10' of armaflex insulation 2" wide self-adhesive tape (from work)

Approx 12" of aluminium 2" wide self-adhesive foil tape (from work)

7 assorted 'jubilee' clips (from work)

I can easily revert back to standard in less than 5 mins.

The heat mat (cut to size) is affixed to the cone via 3 of the jubilee clips, over the top of the armaflex insulation tape.

The K&N filter is held just inside the 6" cone opening via a cut-down (1/2" wide only) piece of armaflex insulation tape on the inside, I hack-sawed 'cuts' (about eight) around the 6" cone spigot, used some foil tape to completely seal the joint externally, then used a jubilee clip to fully hold the filter. Then added more foil tape.
Then the rest of the cone was wrapped with armaflex insulation tape.

The 3" end of the cone (also insulated) just slips nicely into the existing plastic flexible duct on the back of the headlight.

The stainless steel elbow affixes to the samco via one jubilee clip (the gap you can see will disappear when I cut the sleeve down a bit more- its fully sealed anyway), the other end held onto the afm outlet spigot via another jubilee clip.

I arranged the heat-mat such that it is on the side nearest to the front 3 cylinders exhaust manifold.

Incidentally I also used another piece of this heat-mate to bridge the gap in the failing (failed really....) rear heat-shield, held on with paper-clips.....
Having driven with it at high speed, it stays put nicely!!

The heat mat cost me 10 quid nominally 12" square.

As you gather I test drove the car this evening. Placebo effect undoubtedly having an effect, I was most impressed with how the car went. None of that awful 'open' induction roar that I'm not really a fan of, certainly not at motorway speeds! Don't get me wrong, you can still just hear it, but its not intrusive in the slightest.

I will find out on Saturday at our 6 series rolling-road day (organised by James Sohl)whether this arrangement is an improvement on stock. If it does improve output, then I shall insulate the stainless steel as well!

I also changed the drivers side steering arm - one busy evening!!




Edited by UKDaveJ
My 635's.
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